What I did with my weekend - JeepForum.com
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post #1 of 16 Old 05-30-2011, 01:19 AM Thread Starter
igrok
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What I did with my weekend

This is the first Jeep that I've owned and offroaded and my first Wrangler. Let me begin by saying that I am learning every day and wanted to share some of my learning curve. After getting back from URE about 3 weekends ago, I noticed that when I had scraped a pretty big rock with my skid plate, it literally pulled out 2 bolts from the passenger side frame rail. Not quite sure how it could have pulled it out since it was just a scrape, I got under the Jeep and inspected it to find this:



First things first, I checked the rest of the frame and it looked to be solid everywhere else. So I called up my welding buddy (and fellow Jeeper) to see if we could fab a fix for it. He thought about it and came up with this:

http://autorust.com/store/index.php?...=index&cPath=1

The thinking behind capping the whole frame rail mid section was that there was no way to tell what shape the other side was in until the skid plate came off and then getting bolts, nutserts, etc. lined up was going to be a pain. I figured the extra strength across the mid section definitely couldn't hurt.


Common sense is surprisingly, not that common.
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post #2 of 16 Old 05-30-2011, 01:25 AM Thread Starter
igrok
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So I ordered the caps for both the left and right side and had them mailed to my buddy's house. This is what we got:




I didn't want to fuss with nutserts, so we did this:



So we commenced to jacking up the Jeep, putting stands under the body, then taking all the body bolts loose to lower the frame down off the body for more room to work.

We cut out the cancer section:



cleaned the rest of the frame, Then it was just a matter of fitting everything together...



Then the welding...

Then the end product:


Common sense is surprisingly, not that common.
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post #3 of 16 Old 05-30-2011, 02:57 AM
TheBoogieman
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Good job.
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post #4 of 16 Old 05-30-2011, 03:08 AM
Chuck3
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looks nice
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post #5 of 16 Old 05-30-2011, 05:14 AM
greene69
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Looks good, that was some serious rust must have been the salt from the mountain snows.

It's better to be dead and cool than alive and uncool.
Nothing like a permanent reminder of a temporary feeling. I have a few.
4.0 auto, 8.8 rear with detroit locker, 4.10's and 33x 12.50's
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post #6 of 16 Old 05-30-2011, 06:43 AM
TJJP77
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Great job. Fear of rust like this is why I never drive my Jeeps in the winter here in the salt capital of the world.

Chris
'02 Sahara
'06 Rubicon Unlimited
Sienna Jeep Club: Member #15
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post #7 of 16 Old 05-30-2011, 06:59 AM
TheBoogieman
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Ocean salt water from the beach does the same damage.
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post #8 of 16 Old 05-30-2011, 07:05 AM
hefightsfire
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I got to get better friends. You guys did great!

"The problem with quotes on the internet is that you never know if they are real."

Abraham Lincoln
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post #9 of 16 Old 05-30-2011, 08:33 AM
rlkelley
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Quote:
Originally Posted by hefightsfire View Post
I got to get better friends. You guys did great!
thats what i was thinkin.....my friends usually dont show up or just stand around and watch....then have the nerve to ask ME if I have any beer !!!!

gotta love 'em
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post #10 of 16 Old 05-30-2011, 12:22 PM Thread Starter
igrok
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I bought the Jeep 2 years ago, but not being used to cancer like that, never thought to ask where it came from. I think its sea salt rust because the rest of the Jeep is fine. Anyway, you are right about the friends! I've only got one good friend, but I couldn't ask for a better one.

Common sense is surprisingly, not that common.
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post #11 of 16 Old 05-31-2011, 12:14 PM
Turfzilla
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Holy cow! That is some serious rust.

I bet all your future mods will twice as much trouble due to all the bolts you are going to be snapping off.

03 Rubicon, NV 3550, 4" LA, UCF TT, Rear Rock Jock 60, Ultimate 44 w/Artec Truss/gussets and RCV shafts and 37" Irocks
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post #12 of 16 Old 07-01-2011, 01:03 AM Thread Starter
igrok
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Quote:
Originally Posted by Turfzilla View Post
Holy cow! That is some serious rust.

I bet all your future mods will twice as much trouble due to all the bolts you are going to be snapping off.
Not at all. Weird thing is that that was the ONLY place I had rust like that. I went over the rest of the frame to decide if I wanted to dump it and find another Jeep and everything else was solid.

Common sense is surprisingly, not that common.
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post #13 of 16 Old 07-01-2011, 01:56 AM
thirdeye
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Thats a rusty one!

high five!

2004 4.0L I6 TJ BUILD:
http://www.jeepforum.com/forum/f22/h...rdeye-1233347/
1997 2.4L I4 TJ BUILD:
http://www.jeepforum.com/forum/f22/thirdeyes-second-tj-1816002/
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post #14 of 16 Old 07-01-2011, 04:22 AM
Boodyrider
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Critically important: REGULARLY, and especially after wheeling, flush the inside of the frame until water runs perfectly clear with a hose.

97 TJ Sport - 4.0/HP D30 w ARB/8.8 w LS/4.88s; 35s and flat fenders on 2.5 lift

84 CJ7; frame off restoration in progress.

The technical advice you get from me here is worth exactly what you paid me for it. Warranty issues will be reimbursed at double what you paid me for the advice.
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post #15 of 16 Old 07-01-2011, 05:22 AM
djflyy
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That looks great man, I'm going to have to do the same thing as my bolts were ripped out a few years ago, too.

Just a thought, seeing the rust on your TJ... my rust problem was just as bad. I recently stripped it down and coated it with Chassis Saver. Not sure if you know about the product, but it seals against whatever surface you apply it to and prevents future rusting - so it's not just a black paint job. Used about a half-gallon to coat the frame and axles, and do 2 layers. The difference is night and day... Cost me $104 on eBay with Free Shipping from MagnetPaints. They're a vendor on here, too.

Here's a little promo I made of my Jeep. Great experience with the stuff.

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